|Publication number||USRE41650 E1|
|Application number||US 11/847,264|
|Publication date||Sep 7, 2010|
|Filing date||Aug 29, 2007|
|Priority date||Apr 30, 1996|
|Also published as||US5853837, US5993928, US5997680, USRE41649, WO1997040979A1|
|Publication number||11847264, 847264, US RE41650 E1, US RE41650E1, US-E1-RE41650, USRE41650 E1, USRE41650E1|
|Inventors||Ghanshyam H. Popat|
|Original Assignee||Avery Dennison Corporation|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (76), Non-Patent Citations (32), Classifications (50), Legal Events (2)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This is a continuation-in-part of application Ser. No. 08/641,332, filed Apr. 30, 1996 now U.S. Pat. No. 5,997,680, the entire contents of which are hereby incorporated by reference.
The present invention relates to methods of forming business cards and to the constructions of sheets of blank business cards for passing through laser or ink jet printers or copiers.
A sheet of business cards as known in the prior art is shown in
Although the microperforations are thereby small and close together, when the cards 112, after the printing operation thereon, are separated from one another by tearing along the lines, perfectly clean cuts or edges do not result. Rather, the edges 114 are slightly fuzzy as shown in the enlarged view of FIG. 2. These fuzzy edges 114 give the card 112 a less professional look than clean knife cut edges and in certain uses are unacceptable. Currently, business cards have substantially clean edges as they are manufactured by Quick printers (such as KINKOS or PIP). However, the laser and ink jet card products including laser and ink jet card products do not provide clean edges, similar to the main stream business cards.
Directed to remedying problems in the prior art, disclosed herein is an improved business card sheet assembly. The assembly includes, according to one preferred embodiment, a card stock sheet having two parallel pairs of substantial-cut lines extending the length of the sheet and engaging the sheet at both ends thereof. Instead of paper sheets, rolls, fan fold or other print media can be used. The substantial-cut lines extend about 90% through the thickness of the sheet from the front towards the back surface. The sheet is then die cut with short (through-cut) lines extending widthwise between the lines of each pair, or vice versa. The substantial-cut and through-cut lines form on the sheet two columns of business card blanks, with paper waste strips at the side (and end) margins and between the columns. The sheet is then passed through desk top printers, such as laser or ink jet printers or copiers, and the desired indicia is printed on each of the blanks. The printed card blanks are then separated from one another along the substantial-cut and through-cut lines. The borders or edges of the resulting cards are cleaner, superior to the prior art microperforated cards.
To provide for an even cleaner card edge where it was separated along the substantial-cut lines, the substantial-cut lines can be formed by scoring cutting the sheet part way on both faces of the sheet. Thereby, the intact portion of the sheet along these lines will be at the middle (approximately ten or twenty percent) thickness of the sheet. After separation, the torn fibers, being in the middle of the sheet, will be less visible. Also, this construction allows for greater manufacturing control of the formation of the substantial-cut lines to accommodate for different thickness of the paper, depending on where it is taken from the paper roll.
Additionally, a cleaner card edge can be provided by first making the paper more brittle, by densifying its fibers. Preferably, this is done by supercalendering the paper. Supercalendering is a process that has been used by paper manufacturers for many years to produce relatively denser and thinner paper. Instead of supercalendering, the paper can be done by subjecting the paper to chemical or radiation treatments, or other ways as would be apparent to those skilled in the art from this disclosure.
Other objects and advantages of the present invention will become more apparent to those persons having ordinary skill in the art to which the present invention pertains from the foregoing description taken in conjunction with the accompanying drawings.
The sheet assembly includes a sheet of paper 160 such as ten mil thick cardstock available from Simpson Paper Mill in Pomona, Calif. The thickness of the sheet of paper 160 is preferably between seven and twenty mils. A pattern of sheet portions or cards 164 is defined on the sheet by a pattern of lines. The sheet portions 164 are preferably rectangular, but other shapes are within the scope of the invention. For example, the sheet 160 can have dimensions of 8½×11 inches and each of the portions 164 can have the dimensions of a traditional business card (e.g., two by three and a half inches).
The sheet 160 may be a print media, and the print media may be a sheet of paper. This sheet of paper may be bonded or laminated with another paper, film or foil. Further, the sheet may have been subjected to a process making the sheet more brittle. The process may have been a supercalendering process, a chemical process, an irradiation process, an irradiation process which uses ultraviolet radiation or an irradiation process which uses gamma radiation. The process may be applied before, after or simultaneously with the formation of the substantial-cut lines.
Alternatively, the sheet 160 can be supercalendered paper material. It can have a thickness of between one mil to ten mil plus, and preferably between six and thirteen mil. The reason for this somewhat broad thickness range is that some printers, such as ink jet printers, cannot handle heavier or thicker material so that card stock of six, seven or eight mils is needed. On the other hand, other copiers and printers, such as laser printers, can handle thicker materials. The supercalendaring process compresses the paper so that its thickness is reduced by between two and forty percent, for example.
The weight of the paper sheet can be between sixty and one hundred and fifty pounds. While the lower end of that range may be a little too low, the upper end is probably more realistic. One hundred and fifty pound noncalendered paper is typically thirteen to fifteen mil thick and thereby generally too thick to pass through today's printers. However, that same weight paper when supercalendered has a reduced thickness of eleven to thirteen mil, which is thin enough to pass through most printers.
Supercalendering is a process that crushes or compresses the fibers of the sheet, thereby densifying the sheet. Because the sheet is densified, its fibers break or crumble easier along the desired lines. This provides for cleaner edge lines for the business cards.
Although supercalendering is a preferred method of making the paper fibers brittle, other processes are within the scope of this invention. One example is to apply radiation, such as ultraviolet or gamma energy, to the sheet. This can be over the entire sheet evenly or more focused along the desired separation lines. Another process is to apply a chemical to the sheet, such as a dilute acid coating. Again, this can be an even coating on the paper or a more focused application along the desired separation lines. It can be applied before, after or during the formation of the separation lines. For example, if the separation lines are formed by scoring cutting, the chemical may be deposited by application physically on the scoring knives or tools. Separation lines or the entire sheet can be created with stiffening and weakening materials, such as polymers. For example, the sheet can be coated with a very hard polymer, making the entire sheet more brittle, or just the separation lines coated with this brittle polymer.
At least one of the defining lines is a “substantial-cut” line 170, cut along its entire length, substantially but not all of the way through the paper 160; that is, cut from the top surface 174 of the paper approximately ninety percent the way through towards the bottom surface 178. This is shown in enlarged view in
A preferred pattern of defining lines is best shown in FIG. 4. It includes four parallel lengthwise lines 180, 182, 184, 186 extending the length of the sheet 160 and defining two parallel columns 190, 192 with waste strips 196, 198 at the outer edges and one center waste strip 202 between the columns. Spaced parallel widthwise lines 208, 212 extend the widths of the columns 190, 192, but not beyond them. As can be understood from
The lengthwise lines 180, 182, 184, 186 are each substantial-cut lines 170 are disclosed above. And the width-wise lines 208, 212 are preferably each through-cut lines, as best shown in
After the sheet assembly 130 has passed through the printer 134 and the desired indicia 140 printed thereon, the individual cards (or printed media) 164 are separated by tearing or pulling along the four substantial-cut lines. Of course, no further separation is required on the through-cut lines. The side and center waste strips 196, 198, 202 can then be disposed of, as can the end margin strips 240, 244 at the ends of both of the columns.
As described above, relative to
If the paper 160 is a ten mil sheet, the top and bottom scorings cuts 250, 254 can each be two mil, leaving about sixty percent of the fibers intact in the center 258. Alternatively, the scorings cuts can even be 4.75 mil from both sides, leaving the center 258 only one-half mil thick (or any distance in between). The sheet 160 with this thin center 258 will have enough integrity not to fall apart depending on the kind of paper used and the configuration of the printer path. If the path is very convoluted, the one-half mil may not be enough, but for (printers with) straight paths it will likely be sufficient. Half mil thickness may also be sufficient where the paper 160 has long fibers, or where the paper has not been supercalendered or otherwise made brittle as discussed above.
ScoringCutting on both sides tends to give the card (or printed media) when separated from the rest of the sheet a cleaner edge. One reason for this is that the separated fibers are in the middle of the sheet, not hanging out from either the top or bottom. When they are in the middle of the sheet 160 (that is, the middle of the thickness of the paper), they are likely to be less visible to the human eye.
Also, scoring cutting on both sides provides another level of control in the manufacturing process of this assembly. Paper 160 will vary in thickness depending upon whether it is sliced from one end of the paper roll, the middle or the other end. When scoring cutting on two sides, as depicted in
A preferred technique is to score cut the top and bottom cuts 250, 254 simultaneously. However, it is also within the scope of the present invention to make the top and bottom scores cuts at different times. This scoring cutting can be by mechanical means, such as knives, by chemical means or by laser means. Additionally, these score cut lines can be oriented either horizontally or vertically relative to the direction in which the scoring cutting machine is running.
Another sheet embodiment is shown in
An alternative arrangement provides short perforated lines 310, 314, 318 across both side margins 298, 302 and the center gutter 306. Although these short perforated lines provide for easier user access to the (ten) business cards 322 in the two columns, they also make the manufacture of the sheet 270 more difficult and thus may be eliminated if desired. Thus, the perfectly clean through-cut edges are provided on the top and bottom of each of the cards, and the left and right ends are defined by the scored cut lines. Alternatively, the positioning of the score cut lines and through-cut lines can be reversed, if desired.
From the foregoing detailed description, it will be evident that there are a number of changes, adaptations and modifications of the present invention which come within the province of those skilled in the art. However, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof as limited solely by the claims appended hereto.
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|1||Ex Parte Reexamination Certificate issued Jan. 8, 2008 in Application Serial No. 90/007,592, 7 pp.|
|2||Ex Parte Reexamination Examiner filed Mar. 21, 2007 in Application Serial No. 90/007,592, 17 pp.|
|3||Ex Parte Reexamination Examiner Interview Summary filed May 14, 2007 in Application Serial No. 90/007,590, 111 pp.|
|4||Ex Parte Reexamination Examiner Interview Summary filed Nov. 14, 2006 in Application Serial No. 90/007.,90, 4 pp.|
|5||Ex Parte Reexamination Examiner Interview Summary Record filed May 9, 2006 in Application Serial No. 90/007,592, 5 pp.|
|6||Final Office Action Apr. 17, 2009 in Application Serial No. 90/007,590, 13 pp.|
|7||Information Disclosure Statement filed Jun. 16, 2005 in Application Serial No. 90/007,590, 2 pp.|
|8||Information Disclosure Statement filed Jun. 16, 2005 in Application Serial No. 90/007,592, 2 pp.|
|9||Information Disclosure Statement filed Nov. 18, 2005 in Application Serial No. 90/007,592, 5pp.|
|10||Information Disclosure Statement filed Nov. 18, 2005 in Application Serial No. 90/007.590, 5 pp.|
|11||Interview Summary Record filed Dec. 26, 2006 in Application Serial No. 90/007,590, 4 pp.|
|12||Interview Summary Record filed Jun. 7, 2006 in Application Serial No. 90/007,590, 4 pp.|
|13||Interview Summary Record filed Mar. 26, 2007 in Application Serial No. 90/007,592, 3 pp.|
|14||Non-final Office Action Apr. 5, 2007 in Application Serial No. 90/007,590, 111 pp.|
|15||Non-final Office Action dated Mar. 14, 2006 in Application Serial No. 90/007.,90, 43 pp.|
|16||Non-final Office Action Jul. 15, 2008 in Application Serial No. 90/007,590, 12 pp.|
|17||Office Action dated Mar. 1, 2006 in Application Serial No. 90/007,592, 31 pp.|
|18||Office Action in Ex Parte Reexamination dated Jan. 25, 2007 in Application Serial No. 90/007,592, 40 pp.|
|19||Patent for which reexamination is requested filed Jun. 16, 2005 in Application Serial No. 90/007,590, 6 pp.|
|20||Patent for which reexamination is requested filed Jun. 16, 2005 in Application Serial No. 90/007,592, 6 pp.|
|21||Request for Ex Parte Reexamination by Third Party filed Jun. 16, 2005 in Application Serial No. 90/007,590, 15 pp.|
|22||Request for Ex Parte Reexamination by Third party filed Jun. 16, 2005 in Application Serial No. 90/007,592, 19 pp.|
|23||Supplemental Information Disclosure Statement filed Dec. 1, 2005 in Application Serial No. 90/007,592, 5 pp.|
|24||Supplemental Information Disclosure Statement filed Dec. 1, 2005 in Application Serial No. 90/007.590, 9 pp.|
|25||Supplemental Information Disclosure Statement filed Jan. 18, 2006 in Application Serial No. 90/007,592, 4 pp.|
|26||Supplemental Information Disclosure Statement filed Jan. 18, 2006 in Application Serial No. 90/007.590, 4 pp.|
|27||Supplemental Information Disclosure Statement filed Mar. 21, 2006 in Application Serial No. 90/007,592, 4 pp.|
|28||Supplemental Information Disclosure Statement filed Mar. 8, 2006 in Application Serial No. 90/007,592, 4 pp.|
|29||Supplemental Information Disclosure Statement filed May 16, 2005 in Application Serial No. 90/007,592, 3 pp.|
|30||Supplemental Information Disclosure Statement filed May 16, 2006 in Application Serial No. 90/007.590, 2 pp.|
|31||Supplemental Information Disclosure Statement filed Nov. 30, 2005 in Application Serial No. 90/007,592, 4 pp.|
|32||Supplemental Information Disclosure Statement filed Nov. 30, 2005 in Application Serial No. 90/007.590, 4 pp.|
|U.S. Classification||428/43, 428/124, 428/60, 283/105, 428/81, 428/79, 428/156, 428/136, 428/47, 428/59, 428/167, 428/77, 428/192, 428/131, 428/137, 283/103, 428/78|
|International Classification||B42D15/02, B65D65/28, B42D15/10, B42D15/00, B32B29/00, B32B3/30|
|Cooperative Classification||Y10T428/249953, Y10T156/1052, Y10T428/24479, Y10T428/24331, Y10T428/15, Y10T428/193, Y10T428/24777, Y10T156/1082, Y10T428/24322, Y10T428/24314, B32B15/12, B32B29/00, Y10T428/24215, B32B27/10, Y10T428/163, Y10T156/1056, Y10T428/24273, Y10T428/195, Y10T428/2457, B42P2241/22, B42D15/02, B42D5/002, B42D15/0073|
|European Classification||B42D15/00H, B32B27/10, B32B15/12, B32B29/00|
|May 31, 2011||FPAY||Fee payment|
Year of fee payment: 12
|Jul 30, 2013||AS||Assignment|
Owner name: CCL LABEL, INC., MASSACHUSETTS
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:AVERY DENNISON CORPORATION;REEL/FRAME:030909/0883
Effective date: 20130701